Multi-fluid precision calibration pressure source

ABSTRACT

A pressure calibration device can include certain features that allow it to be used with a variety of hydraulic and pneumatic systems. A pressure calibration device can be configured to provide pressure or vacuum, and can have a mode selector for selecting to provide pressure or vacuum. A pressure calibration device can have a volume adjuster configured to modify pressures for hydraulic or pneumatic systems. A pressure calibration device can have a pressure release valve and a bleed valve for adjusting pressure values.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.13/771,006, filed Feb. 19, 2013, which is related to and claims priorityto U.S. Provisional Application No. 61/601,872, filed Feb. 22, 2012. Theentirety of each of the aforementioned applications is herebyincorporated by reference and made a part of this specification.

BACKGROUND

1. Field

Various embodiments disclosed herein relate generally to devices andmethods for calibrating pressures in systems and devices.

2. Related Art

Current calibration pressure devices use various types of volumeadjusters and bleed valves that are usually designed exclusively foreither pneumatic or hydraulic applications. Because of the significantdifferent pressure values involved, valves and adjusters that work wellin hydraulic applications may not work as well in pneumatic applicationsand vice versa.

Many current devices do not operate both as a pressure source and as avacuum source for calibration. Those that do have various limitationsand disadvantages.

SUMMARY OF THE DISCLOSURE

Various embodiments described herein address many of the problems foundin current calibration pressure devices. For example, many currentdevices require metal to metal seals in order to block fluid leaks inhydraulic applications, which operate at very high pressures. Such sealsrequire a very large torque to close, making it difficult to fine tunepressure levels, and they quickly bleed gas when opened in a pneumaticapplication. In various embodiments described herein, a device can havea micro metering bleed valve that can be used for finely controlledrelease of pressure in both pneumatic and hydraulic applications. Amicro metering bleed valve can have delicate components, and in someembodiments a device can have a unidirectional slip clutch that preventsover-tightening of a bleed valve, thereby preventing accidental damage.In some embodiments, a micro metering bleed valve can be combined with apressure release valve to save space and weight.

Additionally, many calibration pressure devices use check valves toallow for uni-directional flow between a pump chamber and a manifold.Check valves are important components of a calibration pressure device.Because calibration pressure devices frequently operate at highpressures, the seals on check valves are frequently prone to rapidfailure. In various embodiments described herein, check valves can haveseals, such as O-rings, that attach to a housing of a check valve ratherthan a poppet of the check valve. This can allow for use of largerO-rings, which decreases the volumetric material deformation of theO-ring, increasing the mean time between failures.

In many calibration pressure devices, volume adjusters are also used toprovide controlled pressure modifications. However, in many currentdevices a volume adjuster that works well for pneumatic applications bymaking a relatively large volume adjustment requires a significanttorque in order to adjust volume in hydraulic applications. Variousembodiments described herein help overcome this problem by providingvolume adjusters with pistons configured for hydraulic applications andpistons configured for pneumatic applications. In some embodiments, thepistons can be concentrically positioned to minimize space and weightconsiderations. In various embodiments, the pistons can be controlledindependently or together as a single combined piston.

Additionally, current devices that do attempt to provide both vacuum andpressure modes often use metal seals used when switching between vacuumand pressure modes, and the operator must provide a significant torqueto switch between modes. Further, in many current devices an operatormust rotate a handle many times to switch between modes. Variousembodiments described herein have a mode selector valve that allows foran operator to easily rotate a handle a predefined amount, such as 120degrees, to alternate between vacuum and pressure modes. This can alsomake it easier for an operator to tell whether a device is configuredfor vacuum mode or pressure mode.

The various components and assemblies described herein can be used forportable calibration pressure devices, portable calibration pressuredevices with hand pumps, and/or non-portable calibration pressuredevices. In various embodiments described herein, a portable calibrationpressure device can include a pump having an inlet and an outlet, amanifold in fluid communication with the pump, a reservoir in fluidcommunication with the pump, and a selector valve. The selector valvecan include a selector valve housing with a first port configured tofluidly connect to the pump inlet and a second port configured tofluidly connect to the pump outlet; a spool positioned at leastpartially within the housing and configured to move axially within thehousing from a first position to a second position; a plurality ofsealing elements positioned within the housing such that when the spoolis in the first position the first port is in fluid communication withthe reservoir and the second port is in fluid communication with themanifold, and when the spool is in the second position the first port isin fluid communication with the manifold and the second port is in fluidcommunication with the reservoir; and a cam member mechanicallyconnected to the spool such that rotating the cam member causes thespool to move axially within the housing.

In some embodiments, the cam member can have an angled slot configuredto receive a pin that connects to the spool. The cam member can beconfigured to rotate no more than 360 degrees to move the spool axiallyfrom the first position to the second position, and in some embodimentsit can rotate approximately 120 degrees to move the spool axially fromthe first position to the second position. In some embodiments, thesealing rings can be O-rings. In some embodiments, the pump can be ahand pump.

In some embodiments, the selector valve housing can have a third port, afourth port, and a fifth port in addition to the first and second ports.In some embodiments, when the spool is in the first position the thirdport can be in fluid communication with the reservoir and can be influid communication through the selector valve with the first port, andthe fourth port can be in fluid communication with the manifold and canbe in fluid communication through the selector valve with the secondport. In some embodiments, when the spool is in the second position thefifth port can be in fluid communication with the reservoir and can bein fluid communication through the selector valve with the second port,and the fourth port can be in fluid communication with the manifold andcan be in fluid communication through the selector valve with the firstport.

In various embodiments described herein, a portable calibration pressuredevice can include a pump having an inlet and an outlet, a manifoldfluidly connected to the pump, a reservoir fluidly connected to thepump, and a selector valve. The selector valve can include a housinghaving a plurality of ports; a spool positioned at least partiallywithin the housing and configured to move axially within the housingfrom a first position to a second position, the spool having at leasttwo recessed sections; a plurality of spacer bushings positioned withinthe selector valve housing such that each port is adjacent a spacerbushing and the spacer bushings adjacent each port comprise at least oneradial hole; a plurality of sealing elements configured to seal againstan outer diameter of the spool, and at least one sealing elementpositioned between adjacent spacer bushings; a first fluid volumebetween a first recessed section of the spool and interior surfaces ofthe sealing elements and spacer bushings; and a second fluid volumebetween a second recessed section of the spool and interior surfaces ofthe sealing elements and spacer bushings. The spool can be locatedwithin the housing such that when the spool is in the first position thereservoir fluidly communicates through one of the first and second fluidvolume to the pump inlet and the manifold fluidly communicates throughthe other of the first and second fluid volume to the pump outlet, andwhen the spool is in the second position the reservoir fluidlycommunicates through one of the first and second fluid volume to thepump outlet and the manifold fluidly communicates through the other ofthe first and second fluid volume to the pump inlet.

In some embodiments, the pump can be a hand pump. In some embodiments,the calibration device can also include a cam member mechanicallyconnected to the spool such that rotating the cam member causes thespool to move axially within the housing. The cam member can have anangled slot configured to receive a pin that connects to the spool. Thecam member can be configured to rotate no more than 360 degrees to movethe spool axially from the first position to the second position, and insome embodiments it can rotate approximately 120 degrees. In someembodiments, the sealing rings can be O-rings. In some embodiments, thesealing elements can remain stationary relative to the selector valvehousing when the spool moves from the first position to the secondposition. In some embodiments, the spacer bushings adjacent each portcan comprise at least one radial hole aligned with the port.

In some embodiments, a first port in the selector valve housing fluidlyconnects to the pump inlet and a second port in the selector valvehousing fluidly connects to the pump outlet. In some embodiments, whenthe spool is in the first position, a third port is in fluidcommunication with the reservoir and is in fluid communication throughthe first fluid volume with the first port, and a fourth port is influid communication with the manifold and is in fluid communicationthrough the second fluid volume with the second port. In someembodiments, when the spool is in the second position, a fifth port isin fluid communication with the reservoir and is in fluid communicationthrough the second fluid volume with the second port, and the fourthport is in fluid communication with the manifold and is in fluidcommunication through the first fluid volume with the first port. Insome embodiments, the spool can have a third position between the firstposition and the second position such that when the spool is in thethird position the reservoir fluidly communicates through one of thefirst and second fluid volume with the manifold.

In various embodiments described herein, a portable calibration pressuredevice can include a pump having an inlet and an outlet, a manifoldfluidly connected to the pump, a reservoir fluidly connected to thepump, and a pressure relief valve. The pressure relief valve can includea housing with a first port in fluid communication with the manifold, asecond port in fluid communication with the reservoir, and a channelconnecting the first port and the second port; a plunger positionedwithin the housing; a sealing tip with a central lumen attached to afirst end of the plunger; a spring element positioned proximate a secondend of the plunger and configured to bias the plunger toward a firstposition in which the plunger pushes a sealing surface of the sealingtip against an opening to the channel, blocking fluid communicationbetween the first port and the second port; a bleed valve needleextending through the plunger and having a distal tip configured to sealwithin the central lumen of the sealing tip; and a handle assembly witha handle, the handle assembly configured to attach to a proximal end ofthe bleed valve needle such that rotating the handle in a firstdirection moves the distal tip of the bleed valve needle into thecentral lumen of the sealing tip to seal the central lumen and rotatingthe handle in a second direction moves the distal tip of the bleed valveneedle away from the central lumen of the sealing tip.

In some embodiments, the pump can be a hand pump. In some embodiments,the sealing tip can screw into the plunger. In some embodiments, thesealing tip can have a curved distal surface. In some embodiments, thecalibration pressure device can include a carrier positioned between theplunger and the handle assembly, and the bleed valve needle can passthrough the carrier and threadedly engage the carrier.

In some embodiments, the handle assembly can also include a clutchbushing defining a plurality of holes and positioned within the handleand attached to the proximal end of the bleed valve needle. The handleassembly can also include a plurality of balls within channels in thehandle, and each ball can be configured to brace against a hole in theclutch bushing to provide a mechanical connection between the handle andthe clutch bushing. The handle assembly can also include a biasingmember configured to bias each ball against a respective hole. In someembodiments, an opening to the holes of the clutch bushing can beasymmetrically chamfered.

In various embodiments described herein, a portable calibration pressuredevice can include a pump, a manifold fluidly connected to the pump, anda volume adjuster. The volume adjuster can have a primary knob with acentral bore, at least a portion of which has internal threading; avolume adjuster housing defining a cylindrical cavity, at least aportion of which has external threading engaging the internal threadingof the central bore, and having a first port that fluidly connects tothe pump and a second port that fluidly connects to the manifold; aprimary piston positioned at least partially within the cylindricalcavity and coupled to the primary knob, the primary piston having acentral channel; a secondary piston positioned at least partially withinthe central channel of the primary piston, the secondary piston andprimary piston blocking an end of the cylindrical cavity to form achamber that fluidly communicates with the first port and the secondport; and a secondary knob mechanically connected to the secondarypiston. Rotating the primary knob can move the primary knob, the primarypiston, and the secondary piston relative to the volume adjusterhousing. Rotating the secondary knob can move the secondary pistonrelative to the primary knob, the primary piston, and the volumeadjuster housing.

In some embodiments, the pump can be a hand pump. In some embodiments,the secondary knob has a non-circular central bore and a portion of thesecondary piston has a non-circular cross section configured to fitwithin the central bore of the secondary knob. In some embodiments, ahollow plunger can be positioned between the primary piston and thesecondary piston. In some embodiments, the secondary piston can haveexternal threading configured to engage internal threading of the hollowplunger. In some embodiments, a cylindrical insert can be positionedbetween the secondary piston and the hollow plunger. The cylindricalinsert can have external threading configured to engage internalthreading of the hollow plunger, and can have internal threadingconfigured to engage external threading of the secondary piston.

In some embodiments, the calibration pressure device can include adifferential screw with a distal section threadedly connected to aninternal bore of the secondary piston, a central section threadedlyconnected to the central channel of the primary piston, and a proximalsection that is mechanically connected to the secondary knob. In someembodiments, the threading on the distal section of the differentialscrew has a smaller thread diameter than the threading on the centralsection of the differential screw. In some embodiments, the threading onthe distal section of the differential screw has a different pitch thanthe threading on the central section of the differential screw.

In various embodiments described herein, a portable calibration pressuredevice can include a pump having an inlet and an outlet, a manifold influid communication with the pump, a reservoir in fluid communicationwith the pump, a mode selector valve configured to selectively movebetween a first position in which the pump inlet draws fluid from thereservoir and the pump outlet pumps fluid to the manifold, and a secondposition in which the pump inlet draws fluid from the manifold and pumpsfluid to the reservoir, and a pressure relief valve. The pressure reliefvalve can include a housing with at least a first port in fluidcommunication with the manifold, a second port in fluid communicationwith the reservoir, and a channel connecting the first port and thesecond port; a sealing tip within the pressure relief valve housing, thesealing tip comprising a central lumen; a biasing member biasing thesealing tip against an opening to the channel, blocking fluidcommunication between the first port and the second port; a bleed valveneedle within the pressure relief valve housing, a distal tip of whichis configured to enter into and block the central lumen of the sealingtip, and a proximal end of the bleed valve needle attached to a handle,such that rotating the handle in a first direction moves the distal tipof the bleed valve needle into the central lumen of the sealing tip toseal the central lumen and rotating the handle in a second directionmoves the distal tip of the bleed valve needle away from the centrallumen of the sealing tip.

In some embodiments, the selector valve can include a selector valvehousing having a first port configured to fluidly connect to the pumpinlet and a second port configured to fluidly connect to the pumpoutlet; a spool positioned at least partially within the housing andconfigured to move axially within the housing from a first position to asecond position; a plurality of sealing elements positioned within thehousing such that when the spool is in the first position the first portis in fluid communication with the reservoir and the second port is influid communication with the manifold, and when the spool is in thesecond position the first port is in fluid communication with themanifold and the second port is in fluid communication with thereservoir; and an actuation member configured to move the spool from thefirst position to the second position.

In some embodiments, the calibration pressure device can also include avolume adjuster. The volume adjuster can have a housing defining acylindrical cavity in fluid communication with the manifold; a primaryknob positioned around and threadedly connected to at least a portion ofthe volume adjuster housing; a primary piston positioned at leastpartially within the cylindrical cavity and mechanically coupled to theprimary knob; and a secondary piston positioned at least partiallywithin the primary piston and mechanically coupled to a secondary knob.The primary and secondary pistons can block the cylindrical cavity toform a chamber within the volume adjuster housing. Rotating the primaryknob can translate the primary piston and the secondary piston relativeto the volume adjuster housing, and rotating the secondary knob cantranslate the secondary piston relative to the volume adjuster housing.

In some embodiments, a portable calibration pressure device can includea hand pump, a manifold fluidly connected to the pump, and a check valvepositioned between the hand pump and the manifold, the check valveconfigured to allow fluid communication between the manifold and handpump in only one direction. The check valve can include a check valvehousing having a bore with a tapered end, a circumferential groovewithin a wall of the tapered end, and an O-ring positioned within thegroove such that at least a portion of the O-ring extends past the wallof the tapered end. The check valve can also include a poppet movablypositioned within the housing, and the poppet can have a first, taperedend and a second end. The check valve can also include a biasing memberconfigured to bias the first end of the poppet into the tapered end ofthe housing bore, thereby forming a seal between the poppet and theO-ring.

BRIEF DESCRIPTION OF THE DRAWINGS

Throughout the drawings, reference numbers may be re-used to indicatecorrespondence between referenced elements. The drawings are provided toillustrate example embodiments described herein and are not intended tolimit the scope of the disclosure.

FIG. 1 illustrates a schematic view of one embodiment of a calibrationpressure hand pump.

FIG. 2 illustrates a schematic of a fluid path of one embodiment of acalibration pressure device configured to provide pressure.

FIG. 3 is a schematic diagram of the main components and fluidconnections of one embodiment of a calibration pressure device.

FIG. 4 is an exploded perspective view of one embodiment of a modeselector valve.

FIG. 5 is a cross section of one embodiment of a selector valve in apressure position.

FIG. 6 is a sectional view of one embodiment of a selector valve in avacuum position.

FIG. 7 is a perspective view of one embodiment of a selector valve.

FIG. 8 is an exploded perspective view of the selector valve of FIG. 7.

FIG. 9A is a perspective sectional view of the selector valve of FIG. 8.

FIG. 9B is a detail view of a section of FIG. 9A.

FIG. 10A is a cross-sectional view of the selector valve of FIG. 9A in apressure position.

FIG. 10B is a cross-sectional view of the selector valve of FIG. 9A in avacuum position.

FIG. 11 is an exploded perspective view of a Pressure Relief Valve andBleed Valve combination.

FIG. 12 is a perspective sectional view of a Pressure Relief Valve andBleed Valve combination.

FIG. 13 is a cross section of a Pressure Relief Valve and Bleed Valvecombination.

FIG. 14 is a detail view of one embodiment of a Pressure Relief Valveand Bleed Valve combination.

FIG. 15 is a cross section of one embodiment of a volume adjuster.

FIG. 16 is a cross section of one embodiment of a volume adjuster.

FIG. 17A is a cross section of one embodiment of a volume adjuster witha fine adjustment knob in a secured position.

FIG. 17B is the volume adjuster of FIG. 17A with the fine adjustmentknob in a released position.

FIG. 18A is a cross section of one embodiment of a volume adjuster witha fine adjustment knob in a secured position.

FIG. 18B is the volume adjuster of FIG. 18A with the fine adjustmentknob in a released position.

FIG. 19 is a perspective view of one embodiment of a volume adjuster.

FIG. 20 is a side view of the volume adjuster of FIG. 19.

FIG. 21 is an exploded perspective view of a piston assembly of thevolume adjuster of FIG. 20.

FIG. 22 is a cross-sectional view of the piston assembly of FIG. 21.

FIG. 23 is an exploded perspective view of the volume adjuster of FIG.20.

FIG. 24 is a cross-sectional view of the volume adjuster of FIG. 23.

FIG. 25A is a perspective sectional view of one embodiment of a poppettype check valve.

FIG. 25B is a detailed view of components of the check valve of FIG.25A.

FIG. 26A is a perspective sectional view of one embodiment of a seattype check valve.

FIG. 26B is a detailed view of components of the check valve of FIG.26A.

DETAILED DESCRIPTION

In various embodiments described herein, calibration pumps can be usedfor calibrating pneumatic and hydraulic gauges, switches and otherinstruments. There are many types of pumps and calibration pressuresources. In some embodiments, the pump can be a hand operated pumpsuitable for portable applications. In some embodiments, the calibrationpumps can combine hydraulic and pneumatic calibration capabilities,providing fine adjustment capabilities for gases and liquids in the sameunit and providing pressure adjustment without requiring excessiveoperator force. This can help allow technicians to carry a singlecalibration device instead of one device for pneumatic and one devicefor hydraulic applications.

In various embodiments described herein, calibration pumps can be usedas a pressure and/or a vacuum source for calibrating pneumatic andhydraulic gauges, switches and other instruments. These embodiments canalso allow a technician to carry a single device for multipleapplications. These embodiments can also be useful for calibratingliquid-filled gauges. The vacuum mode can be used to evacuate media fromthe gauge before calibration, and the pressure mode can be used tocalibrate and return media to the gauge. Use of multiple pumps for thispurpose can take additional time and increase the risk of spills.

In various embodiments described herein, various components ofcalibration pumps have been improved to provide better pressure controladjustability of the pumps and to enable accurate pressure and vacuumoutput during instrumentation calibration. Each of the variouscomponents described herein can individually improve pressure controladjustability, and they can also be combined in any combination within asingle pump.

Device Overview

FIG. 1 illustrates a schematic overview of a multi-fluid calibrationpressure device 100. As used herein, the term fluid can refer to anymaterial or phase capable of fluid motion, such as a gas or liquid. Thedevice can include an actuator mechanism 1, such as a hand pump. Thehandles 55 can be configured according to any standard mechanicalmechanism to drive a piston rod 67 and piston 66 forward when thehandles are squeezed, generating pressure in a fluid chamber 52. Aspring or other biasing mechanism 58 can bias the handles toward an openposition.

A fluid inlet channel 102 can connect to the chamber 52 through a borein the piston rod 67 and piston 66. In some embodiments, a check valve54 can be located inside the piston or piston rod. Various embodimentsof a check valve are described in more detail below. Seals 53 can beinstalled around the piston 66 and piston rod 67 to help prevent escapeof fluid.

The fluid chamber 52 can connect to a manifold 57 via a check valve 56and a channel. The manifold 57 can communicate with a mode selectorvalve 2 (selecting between pressure or vacuum modes), a bleed valve andpressure relief valve combination 27 (PRV), and a volume adjuster 13.Various components are explained in further detail below.

Reference gauge 51 and a Unit Under Test (UUT) 50 can communicate withthe manifold via ports, which may include quick disconnect couplings 60.Other types of connections between the gauges and the manifold can beused, such as threaded connections. Additionally, the gauges can bepositioned at any convenient location on the calibration device.

FIGS. 2 and 3 schematically illustrate the fluid connections betweendifferent components of a multi-fluid calibration pressure device. Fluidconnection can be with rigid tubing or any other sealed conduit. Asillustrated, in some embodiments the mode selector valve 2 can have atleast five fluid connection ports 83 that connect to the system. In someembodiments, the selector valve can have two ports that connect to thepump 1 (one on each side of the pump), two ports that connect to areservoir 59 (which can be a container and/or access to ambient), andone port that connects to the manifold 57. As best visible in FIG. 2,and as described further below, the two ports that connect to the pumpcan maintain fluid communication through the selector valve with therest of the system, and the port that connects to the manifold canmaintain fluid communication to the selector valve and the rest of thesystem. However, the selector valve can have a first position in whichonly one of the ports that connects to the reservoir is in fluidcommunication through the selector valve with the rest of the system. Inthe first position, a “pressure” mode, the mode selector valve 2 directsfluid from the reservoir 59 into the pump 1 inlet and directs thepressurized fluid exiting the pump through the volume adjuster 13 andthe PRV 27 into the manifold 57, where it communicates with the gauges50, 51. In a second position, only the other of the ports that connectsto the reservoir can be in fluid communication through the selectorvalve with the rest of the system. In the second position, a “vacuum”mode, fluid is directed through the manifold 57, through the PRV 27, andthrough the volume adjuster 13 to the pump, where it is pumped back intothe reservoir 59. The first and second positions are described in moredetail below, as are different arrangements of connections to the portsof the selector valve.

In some embodiments, the connection between the selector valve 2 and themanifold 57 can pass through a chamber 25 of the volume adjuster 13 andthrough the PRV and bleed valve 27. The connection between the selectorvalve and the reservoir 59 can pass through the PRV and bleed valve. Thevolume adjuster can increase or decrease the size of the chamber 25,thus modifying the pressure in the line and in the manifold. In someembodiments, the volume adjuster can be configured to enable a coarseadjustment, useful when operating with pneumatic circuits, and a fineadjustment, useful when operating with hydraulic circuits. These aredescribed in more detail below. The PRV and bleed valve can be adjustedto either block communication between the two lines passing through itor to allow varying degrees of communication, allowing the reservoir 59and manifold 57 to partially or completely equalize in pressure, asdesired. The PRV and bleed valve can offer a safety release and finecontrolled bleeding of pressure.

As an example of how a calibration pressure device can be used, in someembodiments a user can connect a calibration pressure device to apressure gauge of a UUT and to a reference gauge. A user can close thePRV and bleed valve, and use the mode selector to select pressure orvacuum mode, as desired. The user can then activate the pump (such as bypumping the handles) to approximate a desired pressure or vacuum level.The user can then use the volume adjuster and bleed valve to fine tunethe pressure until the reading on the reference gauge is approximatelyequal to the desired pressure. The user can then compare readings of thereference gauge and the UUT, and record offsets.

The device can also be used in any application that requiresintroduction of accurate pressure levels over a wide range of valueswith no or minimal flow. For example, it can be used to leak test inmany types of mechanical systems, medical devices, chromatography andmore. It can also be used in applications that require evacuation ofmedia from the UUT and replacement with another media for the durationof the test. The vacuum mode can be used for the evacuation and thepressure mode can introduce fluid back into the unit.

Selector Valve

As mentioned above, a mode selector valve can be used to alternatebetween a pressure mode and a vacuum mode. A selector valve can beattached to a pump inlet and outlet and to other components in a fluidcalibration pressure device, and in the pressure mode certain componentscan receive pressurized fluid while in the vacuum mode those componentscan receive negative pressure (i.e., a vacuum). For example, in someembodiments, in the pressure mode a pump inlet can draw fluid from areservoir (e.g., ambient) through the selector valve, and the pumpoutlet can pump fluid through the selector valve to a manifold. In thevacuum mode, the pump inlet can draw fluid from the manifold through theselector valve and pump fluid to the reservoir (e.g., ambient).

FIGS. 4-6 illustrate one embodiment of a mode selector valve 2.Generally, a mode selector valve functions by using an actuator 8 toprovide linear motion of a spool 5 positioned concentrically and atleast partially within a housing 3. In some embodiments, the actuatorcan be a cam, which can turn rotational motion of the actuator intolinear motion of the spool. Linear movement of the spool and seals canadjust the connections between different ports 83 of the housing, whichcan change the selector valve from a pressure mode to a vacuum mode, asdescribed further below.

In some embodiments, the valve can include O-Ring seals 6, which can bemounted onto grooves 106 on the spool to create a seal between thehousing 3 and the spool 5. Preferably at least five seals 6 are used,and in some embodiments additional seals can be included as backups.Fluid in the internal cavity of the cylindrical housing 3 cancommunicate with other components of the pump through radial ports 83,as discussed above.

The spool may operate at extremely high pressures, and the spool andrings are preferably formed of materials that can support expectedpressures. For example, in some embodiments the spool can be made ofsteel, such as stainless steel 300 series. In some embodiments, theO-rings can have a hardness of at least 70 A durometer, which worksbetter at high pressure, including pressures up to 10,000 psi. In someembodiments, O-rings can have a hardness of at least 90 A durometer. Insome embodiments, lower hardness levels can be used. In someembodiments, O-rings can be formed at least partially of polyurethane.In various embodiments, O-rings such as those provided under the brandname Resilon can be used. O-rings used in other components of the devicecan be of similar properties.

FIG. 4 is an exploded perspective view of one embodiment of a modeselector valve 2, FIG. 5 illustrates a sectional view of the selectorvalve in a first, pressure position, and FIG. 6 illustrates a sectionalview of the selector valve in a second, vacuum position. As illustrated,the selector valve can have a cam 8 with an angled slot 114 that extendsat least partially around a circumference of the cam. In someembodiments, one or both ends of the slot can have a section 108 that isgenerally parallel to the circumference of the cam (i.e., at 90 degreesrelative to the longitudinal axis of the spool). The cam 8 can bemounted on the housing 3 in the orientation shown. Two retaining ringand fiber washer pairs 4 can be positioned on either side of the cam 8to fix its axial position while still allowing it to rotate.

A knob 7 can be positioned around the cam, and can be attached to thecam such that rotating the knob rotates the cam and moves the spoolaxially. For example, when the spool 5 is positioned within the housing3, a dowel pin 61 can be inserted through the cam slots 114, a slot 112in the housing, and a hole 110 in the spool 5. A set screw 9 can bethreaded into an end of the spool 5 to lock the pin 61 to the spool. Theknob 7 can be mounted on top of the cam 8 so that a threaded hole 107 inthe knob is aligned with a counter bore 116 of the cam 8. A ball 12,such as a steel ball, can be positioned into the hole 107, followed by acompression spring 11 and a spring retainer 10, which can be threaded.The ball can also contact a hole 118 in the housing 3. When tightened,the spring retainer 10 can engage the counter bore 116 of the cam 8,thus creating a rigid link to the knob 7 such that the cam rotates whenthe knob rotates. Other mechanical linking mechanisms can also be used.

Rotation of the cam 8 converts rotary motion of the knob 7 into axialmotion of the pin 61, moving the spool 5 from a first position to asecond position and vice versa. FIG. 5 illustrates the spool in a firstposition, and FIG. 6 illustrates the spool moved to a second position.The slot 114 in the cam can be at a fixed angle relative to thelongitudinal axis of the spool, such that linear movement of the spoolis constant relative to rotational movement of the knob and cam. Thesection 108 of the slot that is at approximately 90 degrees to thelongitudinal axis of the spool can create a small portion at one or bothends of cam rotation where no axial motion of the spool occurs. Thesetwo portions, in conjunction with the ball 12 that can engage with ahole 118 in the housing, can create a mechanical lock at the end ofmotion of the knob and cam.

Additionally, the angle of the slot 114 can be configured according to adesired angle of rotation of the knob 7 to move the spool from the firstposition to the second position. For example, in some embodiments, theangle of the slot 114 can be configured such that approximately 90, 120,or 180 degrees of knob rotation are required to move the spool from thefirst position to the second position. In some embodiments, the angle ofthe slot can be configured such that no more than 360 degrees of knobrotation are required to move the spool from the first position to thesecond position.

FIGS. 7-10B illustrate an alternate embodiment of a selector valve, andmore clearly illustrate the relationship between a spool and differentports 83 of the selector valve. The arrangement of ports in thisembodiment can also be used in the selector valve embodiment of FIG.4-6. Similarly, components called out and not specifically identifiedcan be considered to operate the same as similarly labeled components ofFIGS. 4-6 or to be usable according to the same embodiments describedwith respect to FIG. 4-6. For example, the cam can have the same slot114 angles and can be configured to rotate the same amount as describedabove to move the spool from a first position to a second position.

FIG. 7 illustrates a perspective view of a selector valve 2. Asdescribed above, the valve can have a knob 7 that can attach to a spool76 with a plurality of ports 83. The knob can have a decal 34 thatidentifies when the valve has selected a pressure mode and when thevalve has selected a vacuum mode.

FIG. 8 illustrates an exploded view of a selector valve. The selectorvalve can be assembled generally as described above. However, ratherthan having a spool 5 with grooves that receive O-rings, the selectorvalve of this embodiment can have a needle type spool 75. Spacerbushings 81 can be positioned within the selector valve housing 76, andO-rings or seals 6 can be positioned between the bushings inside acentral bore of the housing. Preferably, there are at least six bushingswith at least one ring between each bushing. At least some of thebushings can be positioned adjacent ports 83 of the housing 76.

The seals 6 can be configured to contact and seal against an outerdiameter of the spool 75 and to contact and seal against an innersurface of the housing 76. The spool 75 can have at least one recessedportion 175, such that a volume of space can exist between the recessedportion of the spool and the interior surfaces of the bushings 81 andseals 6. In some embodiments, the spool can have two recessed portionsthat form a first fluid volume and a second fluid volume between therecessed portion of the spool and the interior surfaces of the bushings81 and seals 6. This volume(s) can communicate with the ports 83 viaradial holes 85 in the bushings (visible in FIG. 9B). Each bushing canhave at least one radial hole that passes through the bushings' walls.In some embodiments, an intermediate fluid volume can exist between anouter surface of each bushing and an inner surface of the selector valvehousing 76. In some embodiments, the radial holes of bushings adjacent aport 83 can be in fluid communication with the port via the intermediatefluid volume. In some embodiments, the radial holes of bushings adjacenta port 83 can be aligned with the port.

In some embodiments, locating pins 80 can help maintain the arrangementof seals and bushings in place on one end, and a stopper 82, such as athreaded stopper, can maintain them in position at the opposite end. Insome embodiments, an additional lock pin 78 may be used in order to locka bushing axially in place, thus helping prevent movement under extremepressure conditions. The pin 78 can be inserted into a retaining hole84, sealed with an O-Ring 77, and secured with a retaining ring 79.

FIGS. 9A and 9B illustrate perspective sectional views of the selectorvalve 2. FIG. 9A is a view of the whole valve and FIG. 9B is a detailview of a section that illustrates bushings 81 with their radial holes85. FIGS. 10A and 10B illustrate cross-sectional views of the selectorvalve. In FIG. 10A, the valve is in a first position configured forpressure, and in FIG. 10B the valve is in a second position configuredfor vacuum. In FIGS. 9A-10B the ports 83 are all illustrated as alignedfor ease of illustration. They are not required to be aligned, and canbe in any circumferential position as desired to more easily connectthem to other sections of the calibration device.

In the first position, as illustrated in FIG. 10A, the spool 75 ispositioned with the recessed portions 175 aligned such that a first port83A communicates through the selector valve with a fourth port 83D(e.g., communicates through a first fluid volume), a second port 83Bcommunicates through the selector valve with a fifth port 83E (e.g.,communicates through a second fluid volume), and a third port 83C issealed from communication with other ports through the housing 76 of theselector valve. The first port and third port can communicate with thereservoir 59 and the fourth port can communicate with an inlet to thepump 1 (illustrated in FIG. 3). The second port can communicate with themanifold 57 and the fifth port can communicate with an outlet of thepump (illustrated in FIG. 3). Thus, in the first position, the pump willdraw fluid from the reservoir (or ambient) and pump it to the manifold.

In the second position, as illustrated in FIG. 10B, the spool 75 hastranslated axially such that the first port 83A is sealed fromcommunication with other ports through the housing 76 of the selectorvalve, the second port 83B fluidly communicates through the selectorvalve with the fourth port 83D (e.g., communicates through the firstfluid volume), and the third port 83C fluidly communicates through theselector valve with the fifth port 83E (e.g., communicates through thesecond fluid volume). In this position, the pump will draw fluid fromthe manifold (thus creating a vacuum) and pump it to the reservoir(and/or ambient). The spool can be translated by rotating the knob 7, asdescribed above.

In some embodiments, as the spool 75 transitions between the first andsecond positions it can place a port that communicates with thereservoir 59 into fluid communication with a port that communicates withthe manifold 57. For example, in the illustrated embodiment, when thespool is in a third position between the first and second positions, arecessed portion 175 can be positioned such that the second port 83B,which communicates with the manifold, is also in fluid communicationthrough the selector valve with the third port 83C, which communicateswith the reservoir. This can allow the selector valve to be used as a“quick release” of pressure or vacuum in cases of emergency, quicklyallowing pressure to equalize between the reservoir and the manifold.Pressures in this embodiment can equalize more quickly than when using ableed valve, described in more detail below.

In some embodiments, the ports can be arranged and connecteddifferently, so long as in a first position the pump draws fluid fromthe reservoir (and/or ambient) and pumps it to the manifold, and in asecond position the pump draws fluid from the manifold and pumps it tothe reservoir. For example, in some embodiments, the first port 83A andthird port 83C can communicate with the manifold 57 and the second port83B can communicate with the reservoir 59. In a first position, thesecond port 83B fluidly communicates through the selector valve with thefourth port 83D, which can connect to the pump inlet, and the third port83C fluidly communicates through the selector valve with the fifth port83E, which can connect to the pump outlet. In this position, the pumpwill draw fluid from the reservoir (or ambient) and pump it to themanifold. Similarly, in a second position the first port communicatesthrough the selector valve with the fourth port and the second portcommunicates through the selector valve with fifth port, such that thepump draws fluid from the manifold (thus creating a vacuum) and pumps itto the reservoir (or ambient).

As illustrated, in some embodiments the seals 6 of the selector valve 2remain stationary as the spool 75 moves. This can help maintain the lifeof the seals, which tend to deform under high pressures and can besensitive to surface irregularities, like steps or holes in the housing76. Because the seals don't move relative to the housing and only moverelative to the smooth surface of the spool 75, their service life canbe prolonged. Additionally, this arrangement can make it easier toswitch selector modes under high pressure conditions.

In some embodiments, a selector valve may use a different actuator toaxially push and pull the spool between its operational positions (i.e.,between pressure mode and vacuum mode). Preferably, any actuator usedallows an operator of the device to easily switch between the differentoperational positions. However, the pump can still function with othertypes of selector valves, such as selector valves that require largertorque to operate or are less reliable due to metal to metal sealcontacts that deteriorate over time and quickly bleed gas when loosenedduring pneumatic applications. Additionally, in some embodiments, pumpsthat are designed only for a hydraulic or a pneumatic application maynot have a selector valve.

Pressure Release Valve and Bleed Valve

A pressure release valve and “micro metering” bleed valve assembly (PRVcombination) can be used to control slow bleeding of pressure from thesystem in order to achieve a desired pressure in the manifold. Invarious embodiments described herein, a PRV combination can be used tocontrol bleeding of pressure in both pneumatic and hydraulicapplications. As described herein, the term “bleeding” can refer notjust to lowering the pressure in the system, when the device isoperating in pressure mode, but also letting atmospheric pressure enterthe system when the device is operating in vacuum mode. A PRVcombination can also be used as a valve for safety purposes, and can beconfigured to quickly bring the pressure in the system to atmospheric. APRV combination can also have a uni-directional clutch that prevents thePRV combination from being tightened to a point that damages it. Variouscomponents of the PRV combination can be formed of different materials.Preferably, the internal parts are formed of a hard, corrosion resistantmaterial, such as stainless steel.

Although described herein as a combination, in some embodiments acalibration pressure device can include just a pressure release valve orjust a bleed valve, as described further below.

FIGS. 11-13 illustrate one embodiment of a PRV combination 27.

FIG. 11 illustrates an exploded perspective view, FIG. 12 is aperspective sectional view, and FIG. 13 is a cross-sectional view of aPRV combination 27. The PRV combination can comprise a housing 28, whichis preferably cylindrical. The housing can have radial ports 69,preferably four, which can connect to an internal cavity of the housing.The ports are variously drawn in different locations for illustrationpurposes. Generally, there will be two sets of ports, a set of ports onone side of a seal tip 31, further from a knob assembly 38, and a set ofports on the other side of the seal tip, closer to the knob assembly.The ports can have any orientation relative to each other that makesconnecting the ports to other parts of the device easier. The ports thatare further from the knob assembly can maintain fluid communication witheach other and can connect to the manifold 57. The two ports that arecloser to the knob assembly can maintain fluid communication with eachother and can connect to the reservoir 59 and/or atmospheric pressure.In an assembled calibration pressure device, some of the ports canconnect to other components in the system, such as a selector valve, apump, or a volume adjuster. The PRV combination can bleed pressure byoperating to allow fluid communication between ports connected to themanifold and ports connected to the reservoir and/or atmosphere. In someembodiments, this fluid communication can occur through a channel 169.

The housing 28 can include threaded cylindrical openings at both ends.The end furthest from the knob assembly 38 can be used to secure the PRVcombination to a multi-fluid calibration pressure device. In someembodiments, a pin 29 can be used to provide a more secure attachment.In some embodiments, the end closest to the knob assembly can receive abonnet 36, which can be used to secure a plunger assembly 130 within thehousing 28.

The plunger assembly can include a sealing tip 31 with a central lumen131 through it, a plunger 32, and an O-ring 33 positioned around aplunger groove 132 and configured to create a seal between the plunger32 and an interior surface of the housing 28. The sealing tip can attachto a first end of the plunger. In some embodiments, the sealing tip canhave threading, allowing it to screw into the plunger 32. In someembodiments, the sealing tip can be threaded with left hand thread. Insome embodiments, as illustrated, the sealing tip can have an angleddistal surface. In some embodiments, the sealing tip 31 can have a flatdistal surface that engages an elevated surface of an opening to thechannel 169 that connects the manifold 57 and the reservoir 59. FIG. 14illustrates a detail sectional view of one such embodiment.

The plunger 32 can attach to a carrier 35, preferably with a threadedconnection, and a needle 43 can pass through the carrier and into theplunger. In some embodiments the carrier 35 can have an axial groove 135cut into it, and a set screw 30, such as a set screw with a dog pointtip, can be inserted through a hole in the housing to engage the groove.In some embodiments, the needle 43 can have a smooth cylindrical sectionon its proximal end that engages with a portion of the knob assembly 38,such as a clutch bushing 45. A set screw 68 (visible in FIG. 12) can beused to secure the needle and clutch bushing to each other. The needlecan also have a threaded section that engages an internal thread of thecarrier 35, and a distal tip that can extend into and seal the lumen 131of the sealing tip 31.

In some embodiments, an O-ring 65 can be positioned between the carrier35 and the bonnet 36, thus supporting the plunger assembly. A springelement, such as disc springs 37, can be positioned proximate a secondend of the plunger. For example, the spring element can be positionedbetween the bonnet 36 and an edge of the carrier 35. The spring elementcan provide a compression force between the two components. Also, insome embodiments an O-ring (and possibly a backup ring) 64 can bemounted within the plunger 32 to create a liquid tight seal between theneedle 43 and the internal walls of the plunger 32.

The force of the disc springs can bias the plunger 32 into a firstposition in which the sealing tip 31 is against an opening to thechannel 169 that connects the manifold 57 and the reservoir 59, creatinga seal on the channel opening and blocking fluid communication betweenthe manifold and reservoir. The force or load on the sealing tip 31 canbe adjusted by turning the bonnet 36 in its threads, thus compressing orrelaxing the spring element 37 against the carrier 35. When the pressurein the manifold reaches a “cracking” pressure determined by the load onthe sealing tip, the plunger will be pushed backward into a secondposition in which the sealing tip 31 no longer seals the opening to thechannel 169, allowing for high pressure fluid bleed. Thus, bycompressing or relaxing the disc springs, a maximum desired pressure canbe selected beyond which the sealing tip will be pushed open and highpressure fluid can bleed. This action of the sealing tip forms apressure release valve. In some embodiments in which a device only has apressure release valve, the sealing tip may not have a central lumen.

In embodiments of a PRV combination or where a device only has a bleedvalve, the sealing tip may have the central lumen 131. The lumen 131through the sealing tip 31 can create a fluid path between the manifoldand reservoir when it is not blocked by the bleed valve needle 43, whichcan engage with the back side of the lumen 131. The lumen can be usedfor finely controlled, or “micro metering,” bleeding. Turning the knobassembly 38 in one direction, typically counterclockwise, can cause theneedle to retract, opening the lumen 131 and allowing system fluid tobleed. The knob assembly can include a knob 39, held axially in place bya retaining ring and washer 44, which can be a fiber washer or a steelwasher. The knob can be grasped and used to rotate the knob assembly 38.In some embodiments, as illustrated in FIG. 13, a larger diameter ring46 can be added to the knob. Turning the knob while using the largediameter ring allows for more delicate adjustment of the bleed valveneedle 43. Turning the knob with smaller diameter sections can be usedfor quick fluid discharge and pressure drop when needed. Anotherfunction of the large diameter ring 46 is to protect the knob assemblyfrom debris and to act as a mechanical stop in combination with astopper pin 47 and a lock ring 48.

Tightening the knob 39 too much can cause the needle 43 to damage thesealing tip 31. For example, in some embodiments the sealing tip can bemade of a polymer, such as Vespel or Peek, and over-tightening candeform the tip. To help prevent over-tightening, in some embodiments theknob assembly 38 can include an adjustable slip clutch. The knobassembly can include a clutch bushing 45 within the knob and attached tothe proximal end of the bleed valve needle. Rotating the clutch bushingcan cause the needle 43 to advance against the sealing tip 31. Theclutch bushing can have a plurality of holes 145, which in someembodiments can pass through the clutch bushing. In some embodiments,the clutch bushing has two holes.

In some embodiments, the knob can have channels 147 that align with theholes 145, and a ball 42, which is too large to pass through each hole145, can be positioned within the knob channels and against each hole145 to provide a mechanical connection between the knob and the clutchbushing. The balls can be biased by a biasing member 41, such as aspring, against each hole 145. Rotating the knob 38 causes the balls torotate about a longitudinal axis of the clutch bushing, and the contactbetween the balls and clutch bushing can cause the clutch bushing torotate. As the clutch bushing is tightened, a point will be reachedwhere the force required on the balls to tighten further is greater thanthe force provided by the spring, and the clutch will slip. Anadjustable set screw 40 can be positioned behind each biasing member,such that tightening or loosening the set screw increases or decreasesthe biasing force on the ball, thereby adjusting the point at which theclutch slips.

In some embodiments, openings to the holes 145 can be asymmetricallychamfered such that the chamfer where the balls slip when rotated in atightening direction is shallower than that on the opposite side. Thisresults in a lower torque limit for tightening, while the torquenecessary to loosen the knob 39 and clutch bushing 45 can still beapplied. Additionally, varying the number of holes 145, balls 42, andbiasing members 41 can also affect the maximum torque that the slipclutch can provide. In some embodiments, other aspects of the slipclutch can be designed asymmetrically to provide a torque limit fortightening the knob that is lower than the torque limit for looseningthe knob.

Volume Adjuster

One difficulty in using a volume adjuster to adjust pressure in amulti-fluid pump (e.g., a pump that can be used for hydraulic orpneumatic applications), is that volume adjustments required for apneumatic application can be significantly greater than volumeadjustments required for a hydraulic application. A typical volumeadjuster includes a piston that is moved along a cylinder axis by meansof a threaded knob. Adjustment of manifold pressure in pneumaticapplications requires a relatively large volume to be adjusted, andvolume adjusters for such applications can have pistons with relativelylarge diameters and stroke lengths. Using the same volume adjuster forhydraulic applications requires a significant torque application by theoperator due to the high fluid pressure in the manifold. In addition tomaking adjustments difficult, the required torque can also make itdifficult to fine tune pressure levels. For example, in manyapplications pressure levels are required to be tuned to within 0.1% ofan indicated value.

Various volume adjusters described herein have features that allow themto be easily used for both hydraulic and pneumatic applications withoutrequiring excessive torque. For example, in some embodiments a volumeadjuster can have a coarse adjustment knob configured to control apiston with a surface area appropriate for adjusting pneumatic pressurelevels. A fine adjustment knob can control a piston with a smallersurface area appropriate for adjusting hydraulic pressure levels. Insome embodiments a volume adjuster can have both a coarse and fineadjustment knob and pistons within the same component, and in someembodiments they can be concentrically arranged. This can save space andweight for a fluid calibration device. This can also improve thefunctionality of a device by providing both coarse and fine adjustmentcapabilities within the same handle or knob, making the device easier tolearn and use. Additionally, in embodiments that have both a volumeadjuster and a bleed valve, use of both components can allow foradjusting a pressure source to a pre-determined level quickly and withminimal physical effort.

FIG. 15 illustrates one embodiment of a volume adjuster 13. The volumeadjuster can have a housing 16, a primary piston 17, a secondary piston22 and a primary knob assembly 15 with a central bore 150. The volumeadjuster can have a distal end that includes a chamber 25 and a proximalend that includes the knob assembly 15. The cylindrical housing 16exterior can be partially threaded. It can be sized and configured toengage internal threading in the bore 150 of the knob 15.

The primary, coarse adjustment, piston 17 can be positioned at leastpartially inside a cylindrical cavity of the housing 16 in a concentricmanner. In some embodiments, the primary piston can have a centralchannel or bore that extends through it. In some embodiments, at least aportion of the central bore can have internal threading.

The primary piston can be connected mechanically to the knob 15, such asby two pins or screws 19. A seal, such as an O-ring 23 (and in someembodiments one or more backup O-rings) can be mounted between anexterior body of the piston assembly 17 and internal walls of thehousing 16, thereby creating a fluid tight seal between the chamber 25and other sections of the volume adjuster. One or more radial channelsor ports 24 can create a fluid path between the chamber 25 and the othercomponents of the calibration device. The ports 24 can be arranged inany convenient manner.

A secondary, fine adjustment, piston 22 can be positioned concentricallywithin the primary piston 17 and at least partially within thecylindrical cavity. The distal ends of the primary and secondary pistonscan close the cylindrical cavity of the housing 16 to form the chamber25. Both the fine and coarse pistons can be formed of smooth, hardmaterials, such as stainless steel or sapphire, in order to minimizefriction and extend their working life times. In some embodiments, oneof the pistons can be formed of a first material and another of thepistons can be formed of a second material.

The secondary piston 22 can have a distal section 122 with a smoothexterior surface, a middle section 123 that can have a threadedexterior, and a proximal section 124. The middle section can engageinternal threading in the primary piston 17 to mechanically link the twopistons. An O-ring 62 (and in some embodiments one or more backupO-rings) can be mounted inside the primary piston 17 to seal between thedistal section 122 of the secondary piston 22 and the internal walls ofthe primary piston 17. The proximal section 124 of the secondary piston22 can extend into and engage a secondary knob 18 that has a smallerdiameter than the main knob 15. In some embodiments, the secondary knobcan be positioned at least partially within the primary knob. A setscrew 20 or other securing device can be used to secure the secondaryknob 18 to the secondary piston 22.

Rotating the primary knob 15 can move both the primary piston 17 andsecondary piston 22 relative to the housing 16, thus changing the volumeof the chamber 25 and altering the pressure of fluids connected to thechamber. The friction force between the knob 15 and the housing 16increases when the system pressure is elevated. However, in someembodiments the thread that engages the coarse adjustment piston 17 withthe secondary piston 22 can be smaller in diameter than the threadingbetween the primary knob 15 and the housing 16. In some embodiments, thepitch of the thread that engages the coarse adjustment piston with thesecondary piston can also be smaller than the pitch of the threadingbetween the primary knob and the housing. These differences can meanthat rotation of the fine adjustment knob 18 when the system is underpressure can require less torque compared to the torque required to turnthe large knob, such that the large knob does not move when the smallerknob is rotated. Consequently, if fine adjustments to pressure need tobe made, rotating just the secondary knob 18 can move just the secondarypiston 22 relative to the housing 16. Because the secondary piston issmaller than the primary piston, it will have a lesser effect on thevolume of the chamber and on the consequent pressure of fluids incommunication with the chamber.

FIG. 16 illustrates one embodiment of a volume adjuster 13 that can beused for ultra-fine tune volume adjustment in addition to coarseadjustment. The embodiment of FIG. 16 is assembled similarly to that ofFIG. 15, but the secondary piston 63 does not rotate relative to theprimary piston 17. The secondary piston 63 can slide axially relative tothe primary piston 17. A pin 26 engaged in a slot 126 on an exteriorsurface of the secondary piston can prevent relative rotational motionbetween the two pistons, while still allowing relative axial motion.

The secondary piston 63 of the embodiment of FIG. 16 can have aninternally threaded bore 163 that receives a distal section 120 of adifferential screw 21. A central, threaded section 121 of thedifferential screw can engage internal threading of the primary piston17, and the proximal end of the differential screw can attach to thesecondary knob 18. In some embodiments, the threading on the centralsection of the differential screw can have a thread diameter that isgreater than the thread diameter of the threading on the distal sectionof the differential screw.

The threading of the differential screw can vary between its differentsections. For example, the threading on the distal section 120 of thescrew can have a greater thread diameter than the threading on thecentral section 121. In some embodiments, the threading on the distalsection 120 of the screw can have a different pitch than the treading onthe central section 121 of the screw. In some embodiments, the distalsection is threaded by small diameter thread with a fine pitch, forexample #8-32 UNC-2B. The central section can have a larger diameter andcan be threaded with a coarser thread, for example #10-24 UNC-2A. Thus,rotation of the secondary adjustment knob 18 can create a small axialmotion of the fine adjustment piston 63 relative to the primary piston17, caused by the small difference between the two threads' pitches.This small axial motion can make very small changes to the volume of thechamber 25.

In various embodiments, the secondary adjustment knob can be made indifferent forms to save space and weight for the device. For example,FIGS. 17A and 17B illustrate one embodiment of a volume adjuster 13where the secondary knob 18 can be hidden inside of the primary knob 15.In FIG. 17A, the secondary knob is in a first position within theprimary knob, and in FIG. 17B the secondary knob has been pulled into asecond, released position. A spring 152 can be used to bias thesecondary knob into the first position. The secondary knob can beconfigured such that simply pulling it will release it, or a doubleclick mechanism can be used, as is known in the art.

FIGS. 18A and 18B illustrate another design for a secondary knob 18. Thesecondary knob can be of similar diameter as the primary knob 15, andcan have a projection or pin members 154 that are configured to engage acorresponding recess or recesses 156 of the primary knob 15. Whenengaged, the primary and secondary knobs rotate together. Pulling thefine adjustment knob outwards enables its independent rotation and finevolume adjustment, as described according to various embodiments herein.In both of the embodiments of FIGS. 17A and 17B, and FIGS. 18A and 18B,the secondary shaft 122 can be linked to the secondary knob 18 through aspline mechanism that allows free relative axial movement between thetwo and that transfers rotational force from the knob to the shaft.Also, both of the embodiments of FIGS. 17A and 17B, and FIGS. 18A and18B can be used with any other embodiment of volume adjusters describedherein.

FIGS. 19-24 illustrate another embodiment of a volume adjuster for usewith a calibration pressure device. FIG. 19 is a perspective view of theassembled volume adjuster, which can have the various componentspreviously described. FIG. 20 is a side external view of the samedevice.

As described with respect to various embodiments above, the volumeadjuster 13 can have a first knob 15 configured for coarse volumeadjustment, a second knob 18 configured for fine volume adjustment, anda housing 16 with one or more ports 24 connecting to a chamber withinthe housing.

FIG. 21 illustrates an exploded perspective view of a piston assembly170, which can include a primary piston 17 and a secondary piston 22. Asecondary knob 18, which can control fine volume adjustment, can have acentral bore 180 running through it. At least a portion of the bore canhave a non-cylindrical shape, such that the secondary piston can beinserted into the bore and be rotationally locked relative to thesecondary knob. For example, in the illustrated embodiment the bore 180has a hexagonal cross-section, and the secondary piston 22 can include ahexagonal section 140 that can be configured to fit within the bore suchthat the secondary piston will not rotate relative to the secondary knob18. A retaining ring and washer pair 44 can be attached to the back endof the secondary knob. The washer can be stainless steel, fiber, or ofother materials. The retaining ring and washer pair can also serve as amechanical stop for the secondary piston 22.

In some embodiments, the secondary piston 22 can be positioned within ahollow plunger 91. The plunger can have a section 191 of larger diameterand a section 193 of smaller diameter. Within the larger diametersection, a cylindrical insert 90 can be positioned between the secondarypiston and an interior wall of the plunger in order to help insuresmooth movement of the secondary piston. In some embodiments, theinterior wall of the larger diameter section 191 of the plunger 91 andthe insert 90 can be threaded such that the insert can screw into theplunger. The secondary piston 22 can also have a threaded section 142which can screw into interior threads of the insert 90, such that thesecondary piston, insert, and plunger are all threadedly connected. Insome embodiments, the smaller diameter section 193 of the plunger canhave internal threading which the threaded section of the secondarypiston can screw directly into. In some embodiments, the device does nothave an insert and the secondary piston can be configured to screw onlyinto the plunger. Regardless of whether an insert is present, rotatingthe secondary knob 18 can rotate the piston 22, which moves it relativeto the plunger.

The plunger 91 can be positioned within the primary piston 17. In someembodiments, the primary piston can have internal threads which canreceive external threading 195 on the plunger. Retaining screws 86 canbe used to axially lock the secondary knob 18 to the piston assembly.The primary piston can also have one or more holes 119, which can beused to connect it to a primary knob, as illustrated in FIGS. 23 and 24below. An O-ring 62 (and in some embodiments one or more backup rings)can be positioned around the secondary piston 22 but within the primarypiston 17 to help create a fluid seal. An O-ring 23 (and in someembodiments one or more backup O-rings) can also be mounted around a tipof the primary piston.

FIG. 23 illustrates an exploded perspective view of a volume adjuster13, and FIG. 24 is a cross-sectional view of the volume adjuster. Asillustrated, in addition to the piston assembly 170, the volume adjustercan include a primary knob 15 into which the piston assembly can bepositioned. The piston assembly can be secured in place with pins orscrews 19, which can pass through a hole 129 in the primary knob and thehole 119 of the primary piston 17. The piston assembly can also bepositioned at least partially within a housing 16. The O-ring 23 cancontact an interior surface of the housing to create a fluid sealbetween the housing and the primary piston 17.

In some embodiments, the housing 16 can have a section 160 with externalthreading and the primary knob 15 can have internal threading 151,allowing the two components to be screwed together. A ring 92 and aretaining ring 93 can be positioned around an end of the housing toprovide a mechanical stop for motion of the knob relative to thehousing.

A stop plug 88 can be used to seal an opening at one end of the housing16, thereby forming a chamber 25 between the plug and the primary piston17 and secondary piston 22. In some embodiments, a retaining pin 89 orother locking mechanism can be used to secure the plug to the housing.In some embodiments, one or more O-rings 188 can be positioned around asection of the stop plug to create a fluid seal between the stop plugand the housing.

As in previous embodiments, rotation of the primary knob 15 can causethe primary piston 17 to move relative to the housing, adjusting thevolume in the chamber 25. In some embodiments, the threading can bedesigned such that the required torque to rotate various components issuch that rotation of the primary knob causes both the primary andsecondary pistons to move relative to the housing. In some embodiments,the threading can be configured such that rotation of the primary knobonly causes the primary piston to move relative to the housing. Rotationof the secondary knob 18 can cause just the secondary piston 22 to moverelative to the housing, leading to smaller volume adjustments withinthe chamber 25.

Check Valves

FIGS. 25A through 26B illustrate different check valve designs for usein a fluid calibration pressure device. The check valves can bepositioned as described above, such as in a channel between a fluidchamber and a manifold, or within the piston or piston rod of a pump.Generally, check valves can be positioned anywhere in the device whereflow is desired in only one direction.

FIGS. 25A and 26A illustrate different embodiments of a check valve.

FIGS. 25B and 26B illustrates detail views of a poppet 70 of FIGS. 25Aand 26A, respectively. As described and illustrated with respect to FIG.1, check valves can be positioned in various locations within acalibration pressure device, including within a piston 66 or piston rod67, or between a fluid chamber 52 and a manifold 57 of the device(visible in FIG. 1). The embodiments described herein can be used forany check valve within a fluid calibration pressure device.

In some embodiments, a check valve 56 can include a check valve housing73 with a cavity 173. In some embodiments, the cavity can be a bore witha central axis and a tapered end that can form a valve seat 174. Apoppet 70 can be positioned concentrically within the cavity and becapable of movement along the central axis of the cavity. The poppet canhave a first, tapered end 171 configured to fit within the valve seat174. The tapered end can help allow a poppet to seal against the valveseat in low pressure conditions.

In some embodiments, as illustrated in FIGS. 25A and 25B, the poppet 70can have a groove 182. In some embodiments the groove can be within thetapered end 171 of the poppet. An O-ring 181 can be mounted within thegroove. In some embodiments, a biasing element 72, such as a spring, canattach to a second end of the poppet and bias the poppet against thevalve seat 174. The O-ring can contact the valve seat and create a fluidseal, blocking or substantially blocking fluid flow through the checkvalve 56. This can block or substantially block fluid communicationbetween the chamber 52 and the manifold (visible in FIG. 1). When thecalibration device is pumped such that the piston 66 and piston rod 67drive toward the check valve 56, the increased pressure can drive thepoppet 70 away from the biasing element 72, breaking the seal betweenthe O-ring 181 and the valve seat 174 and allowing fluid to flow pastthe poppet and out of a flow path or channel 172 of the check valve. Thebiasing element 72 can return the poppet to the valve seat 174 whenenough fluid has flowed past for the pressure in the chamber 52 todiminish. A plug 69 can be used to maintain the biasing element inposition and to seal the housing cavity 173. In some embodiments, theplug can be threaded. In some embodiments, the plug can have a distalend that has a reduced diameter that attaches to the biasing element 72.

Because the poppet 70 can move with every stroke of the piston 66, theO-ring can be subject to significant deformation as it moves between aposition in which it seals against the valve seat 174 and a position inwhich it is not sealed. This can be especially true in high pressureconditions, such as during applications with pressures exceeding 3,000psi. When using various embodiments described herein, operatingpressures can exceed 10,000 psi.

FIGS. 26A and 26B illustrate an alternate embodiment of a check valvedesign for use in a fluid calibration pressure device. FIG. 26Aillustrates a check valve 56 and FIG. 26B illustrates a detail view of apoppet 70 used in the check valve. The check valve can operate generallyas described above, but in some embodiments the tapered end 171 of thepoppet 71 does not have a groove but can instead be generally smooth. Insome embodiments, the tapered end of the poppet can have a generallyconical shape.

The valve seat 174 of the housing 74 can have a groove 183 within a wallof the valve seat, such as a circumferential groove extending around anentire circumference of the valve seat. An O-ring 181 can be positionedwithin the groove. In some embodiments, at least a portion of the O-ringcan extend from the groove past the wall of the valve seat. This portionof the O-ring can seal against the surface of the tapered end 171 of thepoppet 71, creating a fluid seal between the poppet and the housing 74,as described above.

Because the groove is within the housing 74, it can be much larger thana groove within the poppet itself. This allows for use of an O-ring 181with a larger diameter without changing the size of the poppet. Forexample, in some embodiments, the design discussed with respect to FIG.25A can use a size 006 O-ring. In some embodiments, the design discussedwith respect to FIG. 26A can use a size 008 O-ring, even if it uses thesame sized poppet. The use of a larger O-ring allows for a lowervolumetric material deformation of the O-ring during use, which can leadto a longer mean time between failures (MTBF) for the O-ring as comparedto the previous embodiment. For example, changing from a size 006 to asize 008 O-ring can decrease volumetric compression from approximately13.4% to approximately 6.6%, a reduction of approximately 50%.

Additionally, by positioning the O-ring within the housing and not agroove on the poppet itself, the O-ring can be increased in size notjust according to diameter but also or alternatively according to itscross-sectional area. Thus, larger and more robust O-rings can be usedthat can greatly diminish the volumetric material deformation of theO-rings during use and lead to a longer MTBF.

Component Relationships

One advantage of the various subassemblies described herein (e.g., thePRV and bleed valve combination, the selector valve, and the volumeadjuster) is that they can easily be modified for use as modular fieldreplaceable units. For example, the subassemblies can have housings thatare capable of being inserted into a fluid calibration pressure deviceand locked in place, such as with a quarter turn mechanism. This canenable repair and preparation of the device for different applicationsin minimal time. It is also possible to use various types of pumps in acalibration device, such as an electrically actuated pump, in place ofthe handle and lever mechanism described above. An electrically actuatedpump can either replace or be incorporated within the handle mechanism.

The subassemblies of a fluid calibration device can be positionedanywhere in the pump and in any order so long as fluid communicationexists between the components and the manifold. Since ergonomicconsiderations are an important part of hand pump design, the desiredplacement of knobs can determine the location of the components. Also,some functions can be separated. For example, the bleed valve can beindependent of the pressure release valve and/or be combined with othersubassemblies, such as the volume adjuster.

Additionally, various subassemblies can be used in other devices thatrequire the features they provide. For example, the volume adjuster canbe used in any device that requires volume adjustment of both pneumaticand hydraulic applications, or in any device that requires both coarseand fine volume adjustments. Similarly, the bleed valve and slip clutchknob can be used in other pneumatic or hydraulic instruments that use“micro metering” valves, whether stationary or portable. Additionally,various subassemblies can be used to replace and improve subassembliesin existing pumps.

The housings used in the subassemblies and in the fluid calibrationpressure device itself are preferably formed of a durable, lightweightmaterial. For example, in some embodiments one or more housings can bemade of aluminum. The housings can also be plated with a coating toalter the properties of the material selected. For example, in someembodiments the housings can be covered with a corrosion resistantanodic coating such as Magnaplate HCR, which can also provide lubricityand surface hardness.

Although this invention has been disclosed in the context of certainpreferred embodiments and examples, it will be understood by thoseskilled in the art that the present invention extends beyond thespecifically disclosed embodiments to other alternative embodimentsand/or uses of the invention and obvious modifications and equivalentsthereof. In addition, while a number of variations of the invention havebeen shown and described in detail, other modifications, which arewithin the scope of this invention, will be readily apparent to those ofskill in the art based upon this disclosure. It is also contemplatedthat various combinations or sub-combinations of the specific featuresand aspects of the embodiments may be made and still fall within thescope of the invention. Accordingly, it should be understood thatvarious features and aspects of the disclosed embodiments can becombined with or substituted for one another in order to form varyingmodes of the disclosed invention. Thus, it is intended that the scope ofthe present invention herein disclosed should not be limited by theparticular disclosed embodiments described above, but should bedetermined only by a fair reading of the claims that follow.

Similarly, this method of disclosure is not to be interpreted asreflecting an intention that any claim require more features than areexpressly recited in that claim. Rather, as the following claimsreflect, inventive aspects lie in a combination of fewer than allfeatures of any single foregoing disclosed embodiment. Thus, the claimsfollowing the Detailed Description are hereby expressly incorporatedinto this Detailed Description, with each claim standing on its own as aseparate embodiment.

1-9. (canceled)
 10. A portable calibration pressure device for use witheither hydraulic or pneumatic systems, said calibration pressure devicecomprising: a pump; a manifold fluidly connected to the pump; and avolume adjuster comprising: a primary knob with a central bore, at leasta portion of the central bore having internal threading; a volumeadjuster housing defining a cylindrical cavity, at least a portion ofthe volume adjuster housing having external threading engaging theinternal threading of the central bore, the housing having a first portthat fluidly connects to the pump and a second port that fluidlyconnects to the manifold; a primary piston positioned at least partiallywithin the cylindrical cavity and coupled to the primary knob, theprimary piston having a central channel; a secondary piston positionedat least partially within the central channel of the primary piston, thesecondary piston and primary piston blocking an end of the cylindricalcavity to form a chamber that fluidly communicates with the first portand the second port; and a secondary knob mechanically connected to thesecondary piston; wherein rotating the primary knob moves the primaryknob, the primary piston, and the secondary piston relative to thevolume adjuster housing; and wherein rotating the secondary knob movesthe secondary piston relative to the primary knob, the primary piston,and the volume adjuster housing.
 11. The calibration pressure device ofclaim 10, wherein the pump is a hand pump.
 12. The calibration pressuredevice of claim 10, further comprising a differential screw with adistal section threadedly connected to an internal bore of the secondarypiston, a central section threadedly connected to the central channel ofthe primary piston, and a proximal section that is mechanicallyconnected to the secondary knob.
 13. The calibration pressure device ofclaim 12, wherein the threading on the distal section of thedifferential screw has a smaller thread diameter than the threading onthe central section of the differential screw.
 14. The calibrationpressure device of claim 12, wherein the threading on the distal sectionof the differential screw has a different pitch than the threading onthe central section of the differential screw.
 15. The calibrationpressure device of claim 10, wherein the secondary knob has anon-circular central bore and a portion of the secondary piston has anon-circular cross section configured to fit within the central bore ofthe secondary knob.
 16. The calibration pressure device of claim 10,further comprising a hollow plunger positioned between the primarypiston and the secondary piston.
 17. The calibration pressure device ofclaim 16, wherein the secondary piston has external threading configuredto engage internal threading of the hollow plunger.
 18. The calibrationpressure device of claim 16, further comprising a cylindrical insertpositioned between the secondary piston and the hollow plunger, thecylindrical insert having external threading configured to engageinternal threading of the hollow plunger, and having internal threadingconfigured to engage external threading of the secondary piston.
 19. Thecalibration pressure device of claim 10, further comprising a pressurerelief valve (PRV) comprising: a PRV housing comprising: a first PRVport configured to fluidly communicate with the manifold; a second PRVport configured to fluidly communicate with a reservoir that is in fluidcommunication with the pump; and a channel connecting the first PRV portand the second PRV port; a plunger positioned in the PRV housing, theplunger having a first end and a second end, the first end comprising asealing tip that comprises a lumen; and a biasing element positionedproximate the second end of the plunger, the biasing element configuredto bias the plunger toward a position in which the plunger engages asealing surface of the sealing tip with an opening to the channel,thereby inhibiting fluid communication between the first PRV port andthe second PRV port.
 20. The calibration pressure device of claim 19,further comprising bleed valve unit comprising: a bleed valve needleextending through the plunger, the bleed valve needle having a distaltip configured to seal within the lumen of the sealing tip; and a handlecoupled to a proximal end of the bleed valve needle; wherein the deviceis configured such that: rotating the handle in a first direction movesthe distal tip of the bleed valve needle into the central lumen of thesealing tip to facilitate sealing the lumen; and rotating the handle ina second direction moves the distal tip of the bleed valve needle awayfrom the lumen of the sealing tip.
 21. A calibration device comprising:a pump; a manifold fluidly connected to the pump; and a volume adjustercomprising: a housing comprising: a first port configured to fluidlyconnect to the pump; and a second port configured to fluidly connect tothe manifold; a primary piston that is threadably engaged with thehousing with a primary thread type; a primary knob coupled with theprimary piston; a secondary piston that is threadably engaged with theprimary piston with a secondary thread type, the secondary thread typehaving a pitch that is less than the pitch of the primary thread type; asecondary knob coupled with the secondary piston; and a variable volumechamber positioned in the housing, the variable volume chamber beingconfigured to fluidly communicate with the first port and the secondport; wherein the primary piston and the secondary piston together forma movable boundary that partially bounds the variable volume chamber;and wherein, in response to movement of the primary knob, both theprimary and secondary pistons move relative to the housing, therebyvarying the volume of the variable volume chamber.
 22. The calibrationpressure device of claim 21, wherein the device is configured such that,when the system is under at least 3,000 psi of pressure, the secondaryknob can be rotated with less torque than the primary knob.
 23. Thecalibration pressure device of claim 21, wherein the primary piston andthe secondary piston are concentrically arranged with each other along acommon longitudinal axis.
 24. The calibration pressure device of claim21, wherein in response to movement of the secondary knob, the secondarypiston moves relative to the primary piston and the housing.
 25. Thecalibration pressure device of claim 21, wherein in response to movementof the secondary knob, the primary piston does not move relative to thehousing.
 26. The calibration pressure device of claim 21, wherein thesecondary knob has a smaller outside diameter than an outside diameterof the primary knob, and the secondary knob extends outwardly from theprimary knob.
 27. The calibration pressure device of claim 21, furthercomprising a pressure relief valve (PRV) comprising: a PRV housingcomprising: a first PRV port configured to fluidly communicate with themanifold; a second PRV port configured to fluidly communicate with areservoir that is in fluid communication with the pump; and a channelconnecting the first PRV port and the second PRV port; a plungerpositioned in the PRV housing, the plunger having a first end and asecond end, the first end comprising a sealing tip that comprises alumen; and a biasing element positioned proximate the second end of theplunger, the biasing element configured to bias the plunger toward afirst position in which the plunger engages a sealing surface of thesealing tip with an opening to the channel, thereby inhibiting fluidcommunication between the first PRV port and the second PRV port. 28.The calibration pressure device of claim 21, further comprising a bleedvalve unit comprising: a bleed valve needle extending through theplunger, the bleed valve needle having a distal tip configured to sealwithin the lumen of the sealing tip; and a handle coupled to a proximalend of the bleed valve needle; wherein the device is configured suchthat: rotating the handle in a first direction moves the distal tip ofthe bleed valve needle into the central lumen of the sealing tip tofacilitate sealing the lumen; and rotating the handle in a seconddirection moves the distal tip of the bleed valve needle away from thelumen of the sealing tip.
 29. The calibration pressure device of claim21, wherein the pump is a hand pump.